Fuel Line Failure and Modification

JimIsbell · 09-12-2009, 09:33 PM

I posted this under repairs and troubleshooting on a thread that was started because of the smell of fuel in the car when the AC was turned on. This happened to me today.

But my solution is a "modification" not just a repair so it belongs on this part of the list.

This should have been a Honda Recall!! Its very dangerous.

This is a very dangerous situation and now we know it has happened to at least two cars. The metal/plastic clamp on the firewall just below the windshield on the two fuel lines, dead center on passenger side, promotes rust on the fuel line by retaining moisture under the plastic part of the clamp and if the line springs a leak it is spraying high pressure fuel into the engine compartment that could end up with a fuel fed fire and possible loss of the car and maybe life. It also sprays fuel onto the insulation on the firewall so that it goes through the firewall into the interior of the car. If you are a smoker it could result in an explosion of the car!!

The fix cost less than $10 (with the fix I used) or up to $850 (Honda replaces line, but NO FIX)

My solution was to remove the clamp, cut the end off the metal fuel line behind the rusted section, then bend it around to a position BELOW the cross member (this requires care and experience to avoid kinking the tubing) instead of above it. Then flare the end with a "double flare tool" The reason for the double flare tool is NOT to do a double flare, but to do the first step of a double flare which will give a reasonable approximation of a "bead" flare. If you dont have a bead flare here it is possible the fuel pressure could push the hose off the metal line. Then using fuel injection hose clamps, re attach the rubber fuel line that goes to the engine.

I would suggest an immediate inspection of ANY car that has not already fixed this problem and maybe even an immediate modification to prevent the problem from occurring. Removal of the plastic clamp is the minimum preventative maintenance that I would do.

Waiting till it springs a leak could be disastrous depending on where you are when it opens up. In 6 pm traffic on a 90 degree day stuck in the center lane and unable to reach the side of the road...and then it bursts into flame??? On a back road, with no tools, -20F outside and no traffic expected till morning?? Or maybe you just pass out from the fumes because you were too tired to notice them on a long trip??

But I am not a mechanic so your solution may vary. These are just comments on what I DID from a DIYer.

joecvt · 09-12-2009, 11:25 PM

I did not have a leak or major rust on the line, but I remember someone posting awhile back warning about the clamp rusting and the fuel lines.

Last Spring, I took off the bracket, cleaned some light corrosion from the fuel line, made an aluminum bracket that would still include the rubber fuel line "bushing" (I guess that is what you could call it).

Before re-assembly, I took black silicone glue and put globs of it inside the bushing and all around so that no moisture could seep in anymore. I think that it is basically sealed now.

If I did not do this fix, I believe some years later the fuel line would corrode enough to create a leak so it is a good idea to check thei fuel line inside that clamp.

JoeCVT = Just your average CVT owner

cyclopsdaman · 12-11-2010, 05:01 PM

I know this has thread has been dead for a while, but I thought I might as well tell everyone that I was smelling some, what I thought was exhaust in the cabin after I changed my cabin filter. Come to find out it was a small gas leak right where you said it would be Upper passenger side). I too removed that overly rusted defective honda piece, cut the line and put a nice new hose on and double clamped it. It may not look pretty but at least I know my car wont blow up now. Luckily only one line was rusted bad.

1/4 scale · 12-11-2010, 11:54 PM

A few pictures would help identify the area. Can any of you guys post some?

**TRI** · 12-12-2010, 11:21 AM

Do you have pics?

02insight · 12-12-2010, 01:14 PM

Quote:

Originally Posted by TRI

Do you have pics?

there are good pictures in this thread about the same issue:
Gas Line Leak - Rust

**TRI** · 12-12-2010, 01:34 PM

Thanks!

davidm · 12-30-2010, 01:29 PM

I may have a similar issue with a 2nd generation insight.

Gasoline smell in passenger cabin?

Atheos · 08-22-2011, 07:13 PM

I've been smelling what I thought was oil for weeks, and had assumed it was from my troubled gearbox. Got under the hood today to do an oil change, and was overwhelmed with the smell and sight of gas all over my engine compartment. I've been driving this fire hazard 2 hours a day! I need to spend more time on this forum, I really wish I had caught this sooner. I agree with the OP, this should be a hazard recall.

LapuRizal · 12-19-2011, 06:58 PM

So it appears that my G1 Insight is having the same problem. I was wondering how long this solution holds up? I live in the northeast with high in the 100's and lows in the 0's with salty roads.

Also, how did you cut the fuel line safely? I can't get my pipe cutter to rotate in this tight space. Has anyone tried replacing the pipe with stainless steel? like this one

Amazon.com: Russell 651104 Stainless Steel Fuel Hose Kit: Automotive

I'd like to keep it as simple as possible (i.e. not draining the tank ) so if you know of a good safe way to remove and "solder" a pipe, let me know! Thanks!